estimation metal part and tooling

INTERNAL USE ONLYINTERNAL USE ONLY 0 Copyright 2012 FUJITSU

Estimation for Metal Part and Tooling

FTS PDG SV SYE 6 Chiang Akina Dec 7th. 2013


IndexItem Content Page

1 Tooling Introduction 2~11

2 Part Data 12

3 Tooling Estimation 13~22

4 Single Part Estimation 23~28

5 Practice 29

6 END 31

PurposeFirst of all; I would like to thank for Jamie’s eff orts, she collected all of

cost data during working here; I just take advanta ge of her data to

integrate my experiences into this metal estimation .

This is a general principle, it can help colleague s know how to estimate

for the Metal Tooling and Part, as well as bargain with vendors easily.


1. Tooling Introduction

L-Stripper 下脫料板

L-Moldbase 下模座

U-stripper 上脫料板

Male-Die 沖頭

U-plate 上固定板Female-Die 下模U-Moldbase 上模座


1.1 Tooling Structure

U-Moldbase上模座

L-Moldbase下模座

U-Stripper上脫料板

L-Stripper下脫料版

Male-Die沖頭

Female-Die下模冲頭

U-Plate上固定板


1.1-1 Function of Tooling Part

Item Part Content

1Mold base模座

It makes the tooling be fixed to the punching machine easily

2U-Stripper上脫料板

It presses the part for location before punching.It pushes back the cut parts after punching

3Male Die衝頭 It is a cutting tool, as well as a forming tool.

4Plate上固定板 It fixes the Die parts and Stripper

5L-stripper 下脫料板

It pre-pushes the part to avoid the interfere.It pushes back the cut part after punching.

6Female-Die 下模衝頭 It is a cutting tool, as well as a forming tool.


1.2 Tooling Type -Blanking (下料)

Before After


1.3 Tooling Type - Cutting (沖孔)

Before After


1.4 Tooling Type - De-burr ( 壓毛邊)

Before After

Chamfer

Chamfer


1.5 Tooling Type - Bending ( 折彎)

Before After


1.6 Tooling Type - Folding ( 反摺)

Before After


1.7 Tooling Type - Forming (抽引)

Before After


1.8 Tooling Type - Progressive (連續模)

Pitch = W+P

BlankingCutting

De-burrBending

Forming

P


Part Data

Blanking Size*L (mm) *W (mm) *T (mm) *Stage/Pitch Q'TY

*Material*Tooling type

1.Stage, 2.Progressive)

2. Part Data

Unbend W

L

Thickness

Material

ITEMSGCC

鍍鋅鋼板SECC

鍍鋅鋼板SPCC

鍍鋅鋼板SUS301不鏽鋼

SUS304不鏽鋼

TIN馬口鐵

1

5

SGCC


3. Tooling Estimation

1. Tooling Material Fee2. Tooling Manufacture Fee3. Tooling Accessary Fee4. Tooling Assembly Fee5. Tooling Design Fee6. Tooling Profit

Tooling Total Cost

Cost Items


3.1 Tooling Material Fee

1. Tooling Material Fee = Sum(Mold Plate+ Base)* N � Stage QuantityOR= Sum(Mold Plate+ Base)*1 � Progressive

Item Material L1 (mm) W1 (mm) H1 (mm) PriceMold Plate SKD11 L1*W1*H1*D* 7.2 $/kg

Mold Base SS41 L1*W1*H1*D*1.51 $/kg

Low Mold (下模) Up Mold (上模)

Mold Base Mold Base

Mold Plate Mold Plate


3.1-1 Tooling Material sizeItem L1 (mm) W1 (mm) H1 (mm)

Mold Plate L+2A=W+2A � Stage

OR=(W+P)*PN+2A �Progressive

Mold Base L+2(A+B)=W+2(A+B) �Stage

OR=(W+P)*PN+2(A+B)�Progressive

A=40mm, B=60 mm, C= 60mm, D=60mm

D D

A

C

WP

PN=Pitch Number


3.2 Tooling Manufacture

Heat Treatment ( 熱處理)

Keeping

Time

Temp.

Critical Temp.(臨界溫度)

Copper

Die

Before Manufacturing After

EDM(放電加工)Milling 銑削

2. Tooling Manufacture Fee: = SUM

Item: Wire-Cutting Heat Treatment CNC/EDM/Milling

Price: L2*H2*0.006 $/mm2 V*D*N*1.66 $/kg Time*16 $/hr

Wire-Cutting (線割)

H2

L2


3.2-1 Wire-Cutting price Wire-Cutting = L2*H2*0.006 $/mm2

L2 = (L+W)* (2+0.5)� Stage toolingOR = (L+W)* (2+2.5) � Progressive or (L+W)>800 mm

H2 = 2C*33= Times � Blanking, De-burr, Cutting, Bending Tooling

W

L

C C

Female die/ L-Stripper/ Male die/ U-Stripper/ U-plate下模冲頭 / 下脫料板 / 冲頭 / 上脫料板 / 上固定板

Part Unbent Size成品展開尺寸


3.2-2 Heat Treatment PriceHeat Treatment =V*D*N*1.6 $/kg; V=Volume, D=Density, N= Stage Quantity,

V = L2*W2*H2

W2 = (W+2A)� Stage toolingOR = (W+P)* PN+2A� Progressive (PN= Pitch number)

H2 =2C- 40mm (Only Die parts have to do the Heat Treatment.)

C W2

Female die/ L-Stripper/ Male die/ U-Stripper/ U-plate下模冲頭 / 下脫料板 / 冲頭 / 上脫料板 / 上固定板

W

L

Part Unbent Size成品展開尺寸

L2


3.2-3 CNC/EDM/Milling Price

CNC/EDM/MillingTime* 16 $/hr

= $250* N� Stage QuantityOR = $300� Progressive


3.3 Tooling Accessary, Assembly

3. Tooling Accessary Fee = (Material fee + Manufacture fee)*0.03

Screw Spring

Assembly

4. Tooling Assembly Fee = Stage Quantity * $200 or Progressive * $200*2


3.4 Tooling Design, Handling & Profit 5. Tooling Design Fee = (Material fee + Manufacture fee)*0.05

1. Tooling Material Fee2. Tooling Manufacture Fee3. Tooling Accessary Fee4. Tooling Assembly Fee5. Tooling Design Fee

6. Handing and Profit = Sum *25%


3.5 Summary

The Metal tooling cost is to calculate

both Material and Wire -cutting fee.


4. Single Part Estimation

1. Part Raw Material Fee2. Part Accessary Fee3. Part Manufacturing Fee4. Transport & Package Fee5. Handling & Profit

Single Part Cost

Cost Items


4.1 Part Raw Material Fee1. Part Raw Material Fee: =L2*W2*T*D*Loss%*(Unit Price)

L2 (mm) W2 (mm) T (mm) Loss % Unit Price $/kg

Material NTD/kg USD/kg

SECC (鍍鋅鋼板) US$1.05SGCC (鍍鋅鋼板) US$1.05SPCC (鍍鋅鋼板) US$1.05SUS301 (不鏽鋼) US$4.94SUS301(0.1t) NT$ 420.00 US$14.48SUS304 (不鏽鋼) US$7.40TIN (馬口鐵) NT$ 75.00 US$2.59

Raw Material

W

L

Thickness

E

D=Density

E

Blanking

E = 5mm+2 +2 3%


4.2 Part Accessary Fee

2. Part Accessary Fee: =SUM

Item Picture Q'ty U/P Price

Usually, Stand-Off is for screw function.

Rivet is to fasten both metal parts together. Metal 1 Metal 2

Screw

Stand-Off US$0.031

Rivet (拉釘) US$0.002

Screw US$0.09


Item Description

Riveting

Stacking

Stand-off Riveted

4.3 Part Manufacturing

1.Pulling

3.Broken

2. Fully Formed

Press

Press


4.3-1 Part Manufacturing Fee3. Part Manufacturing Fee: =Sum

Item Estimation Q'ty U/P Price

Stamping

Riveting

Staking

Stand-off Riveted

Taping

Spot Welding

PrintPainting

Cleaning = (Area)*(U/P)1000000

Stage quantity

Working Plane quantity

US$0.06

US$0.02

US$0.02

US$0.02



Working Plane quantity US$0.02

Working Plane quantity US$0.02

Color Quantity US$0.07By Case

Cleaning Area

N/A

US$1.79/mm2


4.4 Transport & Packing/Handling & Profit4. Transport & Package: Sum( Transport + Packing Fee)

Item U/PTransport N/APacking N/A

1. Part Raw material Fee2. Part Accessary Fee3. Part Manufacture Fee4. Transport &Packing Fee

5. Handing and Profit = Sum5% 20%

*25%


Let’s Practice it

metal estimation


Congratulation ！

You are an expert of estimation for the metal toolin g and part

from now on.

Thanks you


1.3 Tooling Type - Cutting (沖孔)

Before After

estimation metal part and tooling

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